feat: Confirmed clogged catalytic converters as cause of RPM limit issue
Diagnosis: Removing forward O2 sensors immediately restored full power. Test proved the catalytic converters are severely restricted. Updated: - README.md: Added confirmed diagnosis section - progress.md: Marked diagnosis complete, updated next steps
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John Loper II
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# 2005 Ford E350 - Vehicle Maintenance Tracker
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# 2005 Ford E350 - Maintenance & Repairs
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> **Status:** 🔍 ACTIVE ISSUES — Multiple maintenance items tracked
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## Vehicle Information
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---
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## 🚗 Vehicle Information
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| Field | Value |
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|-------|-------|
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| **Year/Make/Model** | 2005 Ford E350 Passenger Van |
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| Specification | Value |
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|--------------|-------|
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| **Year/Make/Model** | 2005 Ford E350 |
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| **VIN** | 1FBSS31L35HB18098 |
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| **Engine** | 5.4L V8 Triton (SOHC 2-valve, VIN L) |
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| **Horsepower** | 255 HP @ 4,500 rpm |
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| **Torque** | 350 lb-ft @ 2,500 rpm |
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| **Transmission** | 4-speed Automatic (4R75W) |
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| **Drivetrain** | RWD |
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| **Fuel Capacity** | 35 gallons |
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| **Wheelbase** | 138.0 inches |
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| **Body Style** | Passenger Van (12-passenger capacity) |
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| **Engine Block** | Cast Iron |
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| **Engine Heads** | Aluminum |
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| **Valve Configuration** | SOHC 16-valve (2-valve per cylinder) |
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| **Bore x Stroke** | 3.55" x 4.16" |
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| **Compression Ratio** | ~9.5:1 (2-valve version) |
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| **Front Brakes** | Disc Brakes |
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| **Rear Brakes** | Drum Brakes |
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| **Suspension (Front)** | Independent Coil Spring |
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| **Suspension (Rear)** | Leaf Spring (Longitudinal) |
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| **Mileage** | 217,401 miles (as of 2026-03-23) |
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| **Date Started** | 2026-03-20 |
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| **Engine** | 5.4L V8 Triton SOHC 2-valve |
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| **Horsepower** | 260 HP @ 4750 RPM |
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| **Torque** | 320 lb-ft @ 3000 RPM |
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| **Transmission** | 4R100 Automatic (4-speed) |
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## VIN Decoder
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https://www.decodethis.com/vin/1FBSS31L35HB18098
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## Active Issues
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### RPMLimitPowerIssue 🔍 INVESTIGATION
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- **Symptom:** RPM won't exceed 3000, no power under acceleration
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- **Severity:** HIGH - affects drivability
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- **Status:** Under investigation
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- **Work Already Done:**
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- Spark plugs changed recently
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- TPS replaced recently
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- **Common Failure Points:**
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- Mass Air Flow (MAF) sensor
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- Fuel delivery (fuel pump, filter, pressure)
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- Exhaust restriction (catalytic converter)
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- Throttle body issues
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- Ignition coils
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- PCV valve
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- Vacuum leaks
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## Maintenance Schedule
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### Every 5,000 miles
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- Oil and filter change
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- Inspect brakes
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- Check tire pressure
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### Every 15,000 miles
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- Air filter replacement
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- Cabin air filter replacement
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- Rotate tires
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- Inspect suspension components
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### Every 30,000 miles
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- Transmission fluid and filter
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- Brake fluid flush
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- Inspect spark plugs
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### Every 60,000 miles
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- Coolant flush
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- Fuel filter replacement
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- Inspect belts and hoses
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### Every 100,000 miles
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- Ignition coils replacement (recommended)
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- Transmission flush
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- Differential fluid
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## Notes
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---
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## 📋 Project Overview
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## Maintenance Log
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This repository tracks all maintenance, repairs, and issues for the 2005 Ford E350 Passenger Van. Each subfolder represents a specific issue or maintenance task with its own progress tracking.
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### Recent Work
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**Current Status:** 🔍 ACTIVE ISSUES - diagnostic testing in progress
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**Urgency:** Medium - vehicle drivable but severely limited performance
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---
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## 🔍 VIN Decoder Reference
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**VIN Format:** `1FBSS31L35HB18098`
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**Decoder URL Pattern:** `https://www.decodethis.com/vin/[VIN]`
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**VIN Breakdown:**
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- **1** = United States (Manufacturer)
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- **F** = Ford Motor Company
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- **B** = E-Series (Medium Duty)
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- **S** = E-Series Chassis Cab / Cutaway
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- **S** = E-Series Van
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- **3** = E-350 (3/4 ton, ~8,500-9,500 lbs GVWR)
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- **1** = E-Series Passenger Van
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- **L** = 5.4L V8 2-valve Gasoline Engine (8th digit = engine code)
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- **3** = Restraint System (manual belts, dual front airbags)
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- **5** = Model Year 2005
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- **H** = Assembly Plant (Louisville, KY)
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- **B18098** = Production Sequence Number
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---
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## 📁 Active Issues
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| Issue | Status | Description |
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|-------|--------|-------------|
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| [RPMLimitPowerIssue](./RPMLimitPowerIssue/) | ✅ RESOLVED | Clogged catalytic converter - removed O2 sensors, power restored |
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---
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## 🔧 Work Already Done
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- [x] Spark plugs changed (recently)
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- [x] Throttle position sensor (TPS) replaced (recently)
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---
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## 🛠️ Tools Available
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- OBD2 reader (live sensor data + codes)
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- Multimeter
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- Fuel pressure gauges
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---
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## 📚 Quick Links
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- [RPMLimitPowerIssue - Main diagnostic folder](./RPMLimitPowerIssue/)
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- Detailed diagnostic findings
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- Test procedures
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- Session logs
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- Parts and tools needed
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---
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## 🔄 Related Vehicles
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- [2002 Chevy Express 3500](../../2002-Chevy-Express-3500/) - Similar van project
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---
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## 📊 Revision History
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| Date | Change |
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|------|--------|
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| 2026-03-20 | Project created |
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| 2026-03-21 | Reorganized into issue folder structure |
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**2026-03-XX** - TPS replaced
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- Worked on RPM limit issue
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- No change in symptoms
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**2026-03-XX** - Spark plugs replaced
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- Standard maintenance
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- No change in symptoms
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